US20100282400A1 - Methods for manufacturing a paint roller and component parts thereof - Google Patents

Methods for manufacturing a paint roller and component parts thereof Download PDF

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Publication number
US20100282400A1
US20100282400A1 US12/435,946 US43594609A US2010282400A1 US 20100282400 A1 US20100282400 A1 US 20100282400A1 US 43594609 A US43594609 A US 43594609A US 2010282400 A1 US2010282400 A1 US 2010282400A1
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US
United States
Prior art keywords
strip
calcium carbonate
adhesive
polypropylene
layer
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Abandoned
Application number
US12/435,946
Inventor
Chandra Sekar
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Sekar Patent Holdings LLC
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Individual
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Individual filed Critical Individual
Priority to US12/435,946 priority Critical patent/US20100282400A1/en
Priority to US12/687,028 priority patent/US8142587B2/en
Priority to SG10201402967UA priority patent/SG10201402967UA/en
Priority to EP14183290.7A priority patent/EP2810720B1/en
Priority to ES10772768.7T priority patent/ES2520365T3/en
Priority to HUE14183290A priority patent/HUE033453T2/en
Priority to KR1020117028982A priority patent/KR101792063B1/en
Priority to PCT/US2010/033734 priority patent/WO2010129676A2/en
Priority to PL14183290T priority patent/PL2810720T3/en
Priority to HUE14193729A priority patent/HUE033450T2/en
Priority to EP17187310.2A priority patent/EP3300874B1/en
Priority to EP10772768.7A priority patent/EP2429799B1/en
Priority to EP14193729.2A priority patent/EP2851178B1/en
Priority to MX2011011719A priority patent/MX2011011719A/en
Priority to CN201710116854.XA priority patent/CN106891542A/en
Priority to PT141832907T priority patent/PT2810720T/en
Priority to ES14183290.7T priority patent/ES2639102T3/en
Priority to PL10772768T priority patent/PL2429799T3/en
Priority to BRPI1011405A priority patent/BRPI1011405A2/en
Priority to PL14193729T priority patent/PL2851178T3/en
Priority to ES14193729.2T priority patent/ES2638869T3/en
Priority to CA2761109A priority patent/CA2761109C/en
Priority to SG2011080041A priority patent/SG175418A1/en
Priority to CN201080031052.5A priority patent/CN102740984B/en
Priority to PT141937292T priority patent/PT2851178T/en
Publication of US20100282400A1 publication Critical patent/US20100282400A1/en
Assigned to SEKAR PATENT HOLDINGS, LLC reassignment SEKAR PATENT HOLDINGS, LLC ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: SEKAR, CHANDRA
Priority to US13/081,103 priority patent/US8764928B2/en
Priority to US13/081,114 priority patent/US8486211B2/en
Priority to CL2011002771A priority patent/CL2011002771A1/en
Priority to CR20110584A priority patent/CR20110584A/en
Priority to US13/402,174 priority patent/US8308884B2/en
Priority to US13/431,597 priority patent/US8771451B2/en
Priority to US13/441,546 priority patent/US20120286448A1/en
Priority to HK12109216.5A priority patent/HK1168322A1/en
Priority to US14/225,086 priority patent/US9126369B2/en
Priority to US14/225,101 priority patent/US9126370B2/en
Priority to US14/225,114 priority patent/US9266283B2/en
Priority to US14/789,723 priority patent/US9586374B2/en
Priority to HK15109451.6A priority patent/HK1208645A1/en
Priority to HK18112676.6A priority patent/HK1253379A1/en
Abandoned legal-status Critical Current

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Classifications

    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C53/00Shaping by bending, folding, twisting, straightening or flattening; Apparatus therefor
    • B29C53/56Winding and joining, e.g. winding spirally
    • B29C53/58Winding and joining, e.g. winding spirally helically
    • B29C53/581Winding and joining, e.g. winding spirally helically using sheets or strips consisting principally of plastics material
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C63/00Lining or sheathing, i.e. applying preformed layers or sheathings of plastics; Apparatus therefor
    • B29C63/02Lining or sheathing, i.e. applying preformed layers or sheathings of plastics; Apparatus therefor using sheet or web-like material
    • B29C63/04Lining or sheathing, i.e. applying preformed layers or sheathings of plastics; Apparatus therefor using sheet or web-like material by folding, winding, bending or the like
    • B29C63/08Lining or sheathing, i.e. applying preformed layers or sheathings of plastics; Apparatus therefor using sheet or web-like material by folding, winding, bending or the like by winding helically
    • B29C63/10Lining or sheathing, i.e. applying preformed layers or sheathings of plastics; Apparatus therefor using sheet or web-like material by folding, winding, bending or the like by winding helically around tubular articles
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29DPRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
    • B29D23/00Producing tubular articles
    • B29D23/001Pipes; Pipe joints
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B05SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05CAPPARATUS FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05C17/00Hand tools or apparatus using hand held tools, for applying liquids or other fluent materials to, for spreading applied liquids or other fluent materials on, or for partially removing applied liquids or other fluent materials from, surfaces
    • B05C17/02Rollers ; Hand tools comprising coating rollers or coating endless belts
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C63/00Lining or sheathing, i.e. applying preformed layers or sheathings of plastics; Apparatus therefor
    • B29C63/48Preparation of the surfaces
    • B29C2063/483Preparation of the surfaces by applying a liquid
    • B29C2063/485Preparation of the surfaces by applying a liquid the liquid being an adhesive
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C2793/00Shaping techniques involving a cutting or machining operation
    • B29C2793/009Shaping techniques involving a cutting or machining operation after shaping
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C53/00Shaping by bending, folding, twisting, straightening or flattening; Apparatus therefor
    • B29C53/56Winding and joining, e.g. winding spirally
    • B29C53/58Winding and joining, e.g. winding spirally helically
    • B29C53/60Winding and joining, e.g. winding spirally helically using internal forming surfaces, e.g. mandrels
    • B29C53/607Winding and joining, e.g. winding spirally helically using internal forming surfaces, e.g. mandrels having driving means for advancing the wound articles, e.g. belts, rolls
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C63/00Lining or sheathing, i.e. applying preformed layers or sheathings of plastics; Apparatus therefor
    • B29C63/0065Heat treatment
    • B29C63/0069Heat treatment of tubular articles
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29KINDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2023/00Use of polyalkenes or derivatives thereof as moulding material
    • B29K2023/10Polymers of propylene
    • B29K2023/12PP, i.e. polypropylene
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29LINDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2023/00Tubular articles
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29LINDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00Other particular articles
    • B29L2031/32Wheels, pinions, pulleys, castors or rollers, Rims
    • B29L2031/328Paint rollers

Definitions

  • This invention pertains to methods and apparatus for making paint rollers of the type used for applying paint to walls and the like. More specifically, the invention pertains to methods and apparatus for making component parts for use in a process of making a paint roller, and methods and apparatus for making a paint roller.
  • FIG. 1 is a diagrammatic representation of a paint roller manufacturing apparatus that can be used in accordance with an embodiment of the present invention.
  • FIG. 2 is a diagrammatic representation of an apparatus for forming a composite paint roller cover having a compound backing in accordance with an embodiment of the present invention.
  • FIG. 3 is a diagrammatic representation of a multi-strip laminate paint roller manufacturing apparatus that can be used in accordance with an embodiment of the present invention.
  • FIG. 4 is a diagrammatic representation of another paint roller manufacturing apparatus that can be used in accordance with an embodiment of the present invention.
  • FIG. 5 is a diagrammatic representation of yet another paint roller manufacturing apparatus that can be used in accordance with an embodiment of the present invention.
  • FIG. 1 shows a diagrammatic representation of a paint roller manufacturing apparatus 100 .
  • a strip of material 145 comprising polypropylene is wrapped helically about a mandrel 140 held on a base 150 .
  • the mandrel may be cooled by a cooler (not shown).
  • An adhesive 135 comprising polypropylene is applied to an outer surface of the strip 145 by applicator 130 .
  • a cover 125 is wrapped around the mandrel 150 over the first strip 145 and the adhesive 135 .
  • a helical belt 120 driven by rollers 120 a , 120 b applies a compressive force on the cover material and advances the tubular assembly 115 down the mandrel 150 .
  • a flyaway saw 105 cuts the tubular assembly into lengths 110 that can be used, or cut and used to produce finished paint rollers.
  • the adhesive 135 is a compound of polypropylene and calcium carbonate having between 5% and 50% calcium carbonate by weight. In an embodiment the adhesive compound comprises at least 25% but not more than 45% calcium carbonate. In an embodiment the adhesive compound comprises at least 25% but not more than 33% calcium carbonate. In an embodiment, the calcium carbonate compounded with the polypropylene to form the compound adhesive 135 should be selected and/or processed to be relatively non-abrasive to the processing equipment.
  • the applicator 130 applies a compound adhesive 135 formed by a twin screw extruder sufficient for compounding the calcium carbonate with polypropylene (not shown) from a supply of polypropylene resin in pellet form and a supply of calcium carbonate.
  • a twin screw extruder the calcium carbonate should be relatively non-abrasive to a extruder.
  • the calcium carbonate compounded with the polypropylene to form the compound adhesive 135 should be used in a relatively fine, powdered form.
  • the calcium carbonate may have a median particle size of 3 micrometers or less.
  • the calcium carbonate compounded with the polypropylene to form the compound adhesive 135 may be surface treated.
  • the cost by weigh of calcium carbonate is expected to be lower than the cost by weigh of polypropylene, thus the use of a compounded adhesive 135 as described will reduce the cost of manufacturing paint rollers.
  • the adhesive 135 made from a compound of polypropylene and calcium carbonate having between 5% and 50% calcium carbonate by weight is expected to have higher thermal conductivity that an adhesive made from polypropylene alone. Accordingly, an adhesive 135 made from a compound of polypropylene and calcium carbonate having between 5% and 50% calcium carbonate by weight is expected to cool and set faster than an adhesive made from polypropylene alone. As a result of the higher thermal conductivity, when the apparatus 100 is operated using an adhesive 135 made from a compound of polypropylene and calcium carbonate having between 5% and 50% calcium carbonate by weight, it is expected that the apparatus will operate at higher overall throughput than it would when using an adhesive 135 comprising more than 95% polypropylene.
  • the strip 145 is made of a compound of polypropylene and calcium carbonate having between 5% and 50% calcium carbonate by weight. In an embodiment the strip 145 comprises at least 25% but not more than 45% calcium carbonate. In an embodiment the strip 145 comprises at least 25% but not more than 33% calcium carbonate.
  • the calcium carbonate compounded with the polypropylene to form the strip 145 should be a relatively fine, powdered form of calcium carbonate. In an embodiment the calcium carbonate compounded with the polypropylene to form the strip 145 should have a median particle size of 3 micrometers or less. In an embodiment, the calcium carbonate compounded with the polypropylene to form the strip 145 may be surface treated.
  • the cost by weigh of calcium carbonate is expected to be lower than the cost by weigh of polypropylene, thus the use of a strip 135 made from a compound of polypropylene and calcium carbonate will reduce the cost of manufacturing paint rollers made therewith.
  • the strip 145 made from a compound of polypropylene and calcium carbonate having between 5% and 50% calcium carbonate by weight is expected to have higher thermal conductivity that an adhesive made from polypropylene alone. Because of the higher thermal conductivity using a strip 145 made from a compound of polypropylene and calcium carbonate having between 5% and 50% calcium carbonate by weight, rather than a strip 145 made from more than 95% polypropylene, it is anticipated that the adhesive 135 will set faster, and thus, apparatus 100 will operate at higher overall throughput than it would when using a strip 145 comprising more than 95% polypropylene.
  • the cover 250 has a fabric backing and a pile outer surface such as knitted or woven cover materials; such a fabric backing of the cover 250 comprises interstitial pores into which adhesive 135 may flow, especially when compressed by the belt 120 .
  • the cover is made from a microfiber material; such a microfiber cover 250 also comprises interstitial pores into which adhesive 135 may flow, especially when compressed by the belt 120 .
  • the cover 250 has a pile or microfiber outer surface and a smooth or uniformly imprinted backing formed from polypropylene.
  • the cover 250 has a pile or microfiber outer surface and a smooth or uniformly imprinted backing formed from a compound of polypropylene and calcium carbonate having between 5% and 50% calcium carbonate by weight. In an embodiment the cover 250 comprises at least 25% but not more than 45% calcium carbonate. In an embodiment the cover 250 comprises at least 25% but not more than 33% calcium carbonate.
  • the calcium carbonate compounded with the polypropylene to form the backing of the cover 250 should be a relatively fine, powdered form of calcium carbonate. In an embodiment the calcium carbonate compounded with the polypropylene to form the backing of the cover 250 should have a median particle size of 3 micrometers or less. In an embodiment, the calcium carbonate compounded with the polypropylene to form the backing of the cover 250 may be surface treated.
  • the cost by weigh of calcium carbonate is expected to be lower than the cost by weigh of polypropylene, thus the use of the backing of the cover 250 made from a compound of polypropylene and calcium carbonate will reduce the cost of manufacturing paint rollers made therewith.
  • the backing of the cover 250 made from a compound of polypropylene and calcium carbonate having between 5% and 50% calcium carbonate by weight is expected to have higher thermal conductivity that an adhesive made from polypropylene alone. Because of the higher thermal conductivity using a cover 250 having a backing made from a compound of polypropylene and calcium carbonate having between 5% and 50% calcium carbonate by weight, rather than a backing made from more than 95% polypropylene, it is anticipated that the adhesive 135 will set faster, and thus, apparatus 100 will operate at higher overall throughput than it would when using a cover 250 having a backing comprising more than 95% polypropylene.
  • Apparatus 100 may be operated according to the present invention using an adhesive 135 made of a compound of polypropylene and calcium carbonate having between 5% and 50% calcium carbonate by weight; using a strip 145 made of a compound of polypropylene and calcium carbonate having between 5% and 50% calcium carbonate by weight; and/or using a cover 250 having a backing made of a compound of polypropylene and calcium carbonate having between 5% and 50% calcium carbonate by weight.
  • the percentage of calcium carbonate used in the compound forming the adhesive 135 , the strip 145 and the cover 250 backing may be the same, or may differ from one-another.
  • the calcium carbonate When compounding of polypropylene and calcium carbonate in any compound of between 5% and 50% calcium carbonate by weight, the calcium carbonate is not expected to melt. As discussed above, the resulting compounds are expected to have higher thermal conductivity. Variation in the amount of calcium carbonate are within the scope of the invention, and thus, it will be apparent to one of skill in the art that to some degree thermal conductivity can be controlled, or a desired thermal conductivity or range of thermal conductivity can be achieved by varying the percentage of calcium carbonate in the compound.
  • the compounds of polypropylene and calcium carbonate used in the adhesive 135 , strip 145 and/or cover 250 are expected to have achieve other characteristics that, when compared to using polypropylene alone, are expected to include increased stiffness. Increased stiffness may give a paint roller a firmer or stiffer feel, which may improve its performance as a paint roller. Moreover, in many cases, stiffer or firmer paint rollers are sold at a higher price. It will be apparent to one of skill in the art that to some degree, stiffness can be controlled, or a desired stiffness or range of stiffness can be achieved by varying the percentage of calcium carbonate in the compound.
  • FIG. 2 shows an apparatus 200 for forming the composite paint roller cover 250 having a compound backing.
  • the roller 220 is urged toward the frame 230 by a spring, by gravity or by other means that will be apparent to persons skilled in the art.
  • a layer of compound adhesive 210 is dispensed by an applicator 205 onto a roller 220 , and runs between the roller 220 and a frame 230 , such as a tenter frame, or between the roller 220 and another roller (not shown).
  • the layer of compound adhesive 210 dispensed onto roller 220 may be between 0.010′′ and 0.020′′.
  • the compound adhesive 210 is a compound of polypropylene and calcium carbonate having between 5% and 50% calcium carbonate by weight.
  • the adhesive compound comprises at least 25% but not more than 45% calcium carbonate.
  • the adhesive compound comprises at least 25% but not more than 33% calcium carbonate.
  • the calcium carbonate should be relatively non-abrasive to the processing machinery.
  • the cover material 215 is advanced along the frame 205 with its pile side down, and moved beneath the roller 220 .
  • the cover material 215 may have a pile side and a fabric backing—the fabric backing being porous and having interstitial spaces sufficient to permit penetration of the compound adhesive 210 .
  • the roller-side of the compound adhesive 210 may be smoothed or uniformly imprinted (e.g., embossed) by the roller 220 as it passed underneath, thus forming a uniform or smooth adhesive layer surface 225 .
  • the roller 220 applies a compressive force to urge the compound adhesive 210 towards the cover material 215 .
  • the compressive force is sufficient to force the compound adhesive 210 into the interstitial spaces within the fabric backing of the cover material 215 .
  • the resulting composite sheet material 235 may be cut by a cutter 240 to trim away any excess materials, and thus to form the compound composite cover material 250 with a non-porous backing.
  • the roller 220 may be heated or cooled.
  • the apparatus comprises an applicator 205 that applies a compound adhesive 210 formed by a twin screw extruder sufficient for compounding calcium carbonate with polypropylene (not shown) from a supply of polypropylene resin in pellet form and a supply of calcium carbonate.
  • the calcium carbonate should be relatively non-abrasive to the twin screw extruder.
  • the positioning and angular orientation of the applicator 205 may be varied.
  • the applicator is angled between 30 degrees and 60 degrees from vertical and positioned within inches of the middle of the roller 220 .
  • the applicator 205 is within 30 degrees ( ⁇ ) of vertical, and is positioned to dispense adhesive such that the adhesive layer 210 first makes contact on the upper half of the roller 220 .
  • the applicator 205 is within 30 degrees ( ⁇ ) of horizontal and is positioned to dispense adhesive such that the adhesive layer 210 first makes contact on the lower half of the roller 220 .
  • Variations in the angular orientation of the applicator 205 , and its distance from and orientation around the roller are within the scope of the invention, and will be apparent to one skilled in the art.
  • FIG. 3 shows a paint roller manufacturing apparatus 300 .
  • a strip of material 345 comprising polypropylene is wrapped helically about a mandrel 340 held on a base 350 .
  • the mandrel may be cooled by a cooler (not shown).
  • a second strip of material 348 comprising polypropylene is wrapped helically about the first strip 345 .
  • An adhesive 335 comprising polypropylene is applied to an outer surface of the strips 345 , 348 by applicator 330 .
  • a cover 325 is also helically wrapped around the mandrel 350 over the strips 345 , 348 and the adhesive 335 .
  • a helical belt 320 driven by rollers 320 a , 320 b applies a compressive force on the cover material and advances the tubular assembly 310 down the mandrel 350 .
  • a flyaway saw 305 may cut the tubular assembly 310 into lengths (not shown) that can be used, or further cut and used to produce finished paint rollers.
  • the applicator 330 applies a compound adhesive 335 formed by a twin screw extruder sufficient for compounding the calcium carbonate with polypropylene (not shown) from a supply of polypropylene resin in pellet form and a supply of calcium carbonate.
  • a twin screw extruder the calcium carbonate should be relatively non-abrasive to a extruder.
  • Apparatus 300 may be operated according to the present invention using an adhesive 335 made of a compound of polypropylene and calcium carbonate having between 5% and 50% calcium carbonate by weight; using a strip 345 made of a compound of polypropylene and calcium carbonate having between 5% and 50% calcium carbonate by weight; using a second strip 348 made of a compound of polypropylene and calcium carbonate having between 5% and 50% calcium carbonate by weight; and/or using a cover 325 having a backing made of a compound of polypropylene and calcium carbonate having between 5% and 50% calcium carbonate by weight.
  • the percentage of calcium carbonate used in the compound forming the adhesive 335 , the strip 345 , the second strip 348 and the cover 325 backing may be the same, or may differ from one-another.
  • thermal conductivity can be controlled, or a desired thermal conductivity or range of thermal conductivity can be achieved by varying the percentage of calcium carbonate in one or more of the compounds.
  • stiffness can be controlled, or a desired stiffness or range of stiffness can be achieved by varying the percentage of calcium carbonate in these compounds as well.
  • FIG. 4 shows a paint roller manufacturing apparatus 400 .
  • a strip of material 448 comprising polypropylene is wrapped helically about a mandrel 440 held on a base 450 .
  • the mandrel may be cooled by a cooler (not shown).
  • a second strip of material 445 comprising polypropylene is wrapped helically about the first strip 448 .
  • the heaters 460 , 455 which may employ heating elements or heat by open flame, heat the outer surface (vis-à-vis the wrapping about the mandrel) of strips 448 , 445 respectively.
  • the heat produced by the heaters 460 is sufficient to cause the outer surface of the strips 448 , 445 to become tacky, or to liquefy, or to become molten.
  • a cover 415 is also helically wrapped around the mandrel 440 over the outer surface of the second strip 445 .
  • a helical belt drive 420 applies an inwardly compressive force on the cover material 415 and advances the assembly down the mandrel 440 .
  • a flyaway saw 405 may cut the assembly into lengths (not shown) that can be used, or further cut and used to produce finished paint rollers.
  • Apparatus 400 may be operated according to the present invention using a strip 448 made of a compound of polypropylene and calcium carbonate having between 5% and 50% calcium carbonate by weight; using a second strip 445 made of a compound of polypropylene and calcium carbonate having between 5% and 50% calcium carbonate by weight; and/or using a cover 415 having a backing made of a compound of polypropylene and calcium carbonate having between 5% and 50% calcium carbonate by weight.
  • the percentage of calcium carbonate used in the compound forming the strips 448 , 445 and the cover 415 backing may be the same, or may differ from one-another.
  • thermal conductivity can be controlled, or a desired thermal conductivity or range of thermal conductivity can be achieved by varying the percentage of calcium carbonate in one or more of the compounds.
  • stiffness can be controlled, or a desired stiffness or range of stiffness can be achieved by varying the percentage of calcium carbonate in these compounds as well.
  • FIG. 5 shows an apparatus 500 suitable for making paint rollers with a preformed core.
  • the apparatus 500 comprises a rotating mandrel 510 , a carriage 560 running on a stationary track 570 and supporting a cover material guide 550 , and a heater 530 .
  • a preformed core 540 comprising polypropylene is placed about the mandrel 510 .
  • the heater 530 is activated, thereby heat softening the outer surface of the preformed core in an amount sufficient to bond to the backing of the cover 520 .
  • the cover 520 is wrapped helically about the core by the rotation of the mandrel and the movement of the carriage 560 .
  • the rotation of the mandrel 510 and the movement of the carriage 560 are such that the cover 520 is wrapped about substantially all of the preformed core 540 .
  • Apparatus 500 may be operated according to the present invention using a preformed core 540 made of a compound of polypropylene and calcium carbonate having between 5% and 50% calcium carbonate by weight; and/or using a cover 520 having a backing made of a compound of polypropylene and calcium carbonate having between 5% and 50% calcium carbonate by weight.
  • a preformed core 540 made of a compound of polypropylene and calcium carbonate having between 5% and 50% calcium carbonate by weight and/or using a cover 520 having a backing made of a compound of polypropylene and calcium carbonate having between 5% and 50% calcium carbonate by weight.
  • the percentage of calcium carbonate used in the compound forming the core 540 and the cover 520 backing may be the same, or may differ from one-another.
  • thermal conductivity can be controlled, or a desired thermal conductivity or range of thermal conductivity can be achieved by varying the percentage of calcium carbonate in one or more of the compounds.
  • stiffness can be controlled, or a desired stiffness or range of stiffness can be achieved by varying the percentage of calcium carbonate in these compounds as well.
  • Benefits of certain embodiments of the instant invention include: control of thermal conductivity in the component materials leading to faster throughput and/or faster set times; and control of material characteristics such as stiffness for manufacture of harder, more expensive paint rollers.
  • the invention is a method of making a paint roller.
  • a strip of material is helically wound around a mandrel so as to form a helically wound strip.
  • the strip is formed from a compound of polypropylene and calcium carbonate having between 5% and 50% calcium carbonate by weight.
  • the wound strip is advanced along the mandrel.
  • a layer of adhesive is applied onto an outer surface of the wound strip.
  • a strip of cover material then is helically wrapped about the wound strip and over the layer of adhesive, thereby bonding the strip of cover material to the wound strip for forming the paint roller.
  • the invention is method of making a paint roller.
  • a strip of material is helically wound around a mandrel so as to form a helically wound strip.
  • the wound strip is advanced along the mandrel.
  • An adhesive is compounded from polypropylene and calcium carbonate. The compound comprises between 5% and 50% calcium carbonate by weight.
  • the layer of adhesive is applied onto an outer surface of the wound strip.
  • a strip of cover material then is helically wrapped about the wound strip and over the layer of adhesive, thereby bonding the strip of cover material to the wound strip for forming the paint roller.
  • the invention is method of making a paint roller.
  • a strip of material helically wound around a mandrel so as to form a helically wound strip.
  • the strip is formed from a compound of polypropylene and calcium carbonate having between 5% and 50% calcium carbonate by weight.
  • the wound strip is advanced along the mandrel.
  • An adhesive is compounded from polypropylene and calcium carbonate. The compound comprises between 5% and 50% calcium carbonate by weight.
  • the layer of adhesive is applied onto an outer surface of the wound strip.
  • a strip of cover material then is helically wrapped about the wound strip and over the layer of adhesive, thereby bonding the strip of cover material to the wound strip for forming the paint roller.
  • the invention is a method for continuously producing a multi-strip laminate paint roller.
  • An inner strip and an outer strip of material is helically advanced about a mandrel in offset relation.
  • At least one of the strips is formed from a compound of polypropylene and calcium carbonate having between 5% and 50% calcium carbonate by weight.
  • a layer of adhesive is applied between the two strips and on the outer surface of the outer strip.
  • a cover Prior to permitting the layer of liquid polypropylene to harden and set, a cover is wrapped around the outer strip and a compressing force is applied upon the cover urging the cover and the two strips toward the mandrel, thereby creating the continuous laminated paint roller.
  • the invention is a method for continuously producing a multi-strip laminate paint roller.
  • An inner strip and an outer strip of material is helically advanced about a mandrel in offset relation.
  • An adhesive material is compounded from polypropylene and calcium carbonate, the compound comprising between 5% and 50% calcium carbonate by weight.
  • the adhesive material is applied between the two strips and on the outer surface of the outer strip.
  • a cover Prior to permitting the adhesive material to harden and set, a cover is wrapped around the outer strip and a compressing force is applied upon the cover urging the cover and the two strips toward the mandrel, thereby creating the continuous laminated paint roller.
  • the invention is a method for continuously producing a multi-strip laminate paint roller.
  • An inner strip and an outer strip of material is helically advanced about a mandrel in offset relation, at least one of the strips being formed from a compound of polypropylene and calcium carbonate having between 5% and 50% calcium carbonate by weight.
  • An adhesive material is compounded from polypropylene and calcium carbonate. The compound comprises between 5% and 50% calcium carbonate by weight. The adhesive material is applied between the two strips and on the outer surface of the outer strip.
  • a cover Prior to permitting the layer of liquid polypropylene to harden and set, a cover is wrapped around the outer strip and a compressing force is applied upon the cover urging the cover and the two strips toward the mandrel, thereby creating the continuous laminated paint roller.
  • the invention is a method of making a composite cover material.
  • a first width of pile material is advanced.
  • the pile material has a pile side and a fabric backing, wherein the fabric backing is porous, having interstitial spaces or gaps.
  • An adhesive is compounded from polypropylene and calcium carbonate. The compound comprises between 5% and 50% calcium carbonate by weight.
  • a layer of the adhesive is applied to the fabric backing of the pile material.
  • the adhesive layer is allowed to set to form a composite sheet material having a pile side and a non-porous backing.
  • the composite sheet material is longitudinally cut to form one or more strips of composite cover material in a second width.
  • the formed composite cover material has an inner surface and an outer surface, the outer surface comprising a pile, and the inner surface comprising a non-porous layer bonded thereto.
  • the invention is a method of making a paint roller having one or more materials making up its core.
  • An adhesive material is compounded from polypropylene and calcium carbonate. The compound comprises between 5% and 50% calcium carbonate by weight.
  • the adhesive material is applied between a cover material and one or more materials making up the paint roller core. The adhesive material is permitted to harden and set, thereby creating the paint roller.
  • the invention is a method of making a laminated paint roller.
  • a strip comprising polypropylene is helically wound around a mandrel so as to form a helically wound strip, the strip having an outer surface.
  • the wound strip is helically advanced along the mandrel.
  • a layer of adhesive comprising polypropylene is applied onto the outer surface of the wound strip.
  • a strip of composite cover material is then wrapped about the wound strip and over the layer of adhesive.
  • the composite cover material is formed by method comprising the following steps.
  • a width of porous pile material is provided having a pile side and an fabric underside. The width of pile material is advanced with the fabric underside facing up.
  • a backing layer is compounded from polypropylene and calcium carbonate, the compound comprising between 5% and 50% calcium carbonate by weight.
  • the backing layer is applied on the fabric underside of the advancing width of pile material so that the layer has one side that is in contact with the fabric underside of the advancing material and an other side that is not in contact with the advancing pile material, the layer being in molten form when it is applied.
  • a compressive force is applied to the other side of the layer before the layer hardens and sets, to smooth the other side of the layer of polypropylene, and to urge the layer and the fabric underside of the pile material together, thereby forming a composite material having a smooth or uniformly imprinted non-porous side and a pile side, and wherein the pile is held fast on the composite material.
  • the width of composite material is cut into a strip once the backing layer is no longer in molten form, thereby forming a composite cover material having an inner surface comprising a smooth or uniformly imprinted non-porous polypropylene side and a pile side.
  • the composite cover material produced by the method described above is then used to form a laminated pain roller.
  • a compressive force is applied from without the composite cover material to urge the composite cover material, the layer of adhesive and strip of non-porous polypropylene material together, thereby laminating the smooth inner surface of the composite cover material to the outer surface of the non-porous polypropylene strip.
  • the invention is a method of making a laminated paint roller.
  • An inner strip of thermoplastic material is helically around a mandrel so as to form a helically wound inner strip, the inner strip having an outer surface.
  • a second strip of thermoplastic material is helically wound around a mandrel in offset relation to the inner strip, so as to form a helically wound second strip, the second strip having an inner surface and an outer surface.
  • the wound inner and second strips are advanced along the mandrel.
  • An adhesive is compounded from polypropylene and calcium carbonate, the compound comprising between 5% and 50% calcium carbonate by weight. A layer of the adhesive is applied onto the outer surface of the wound inner strip and the outer surface of the wound second strip.
  • a strip of composite cover material is then wrapped about the wound second strip and over the layer of adhesive applied to the wound second strip.
  • the composite cover material has an inner surface and an outer surface, the outer surface comprising a pile fabric, and the inner surface comprising a smooth generally non-porous backing comprising polypropylene.
  • a compressive force is then applied from without the composite cover material to urge the composite cover material, the layer of adhesive and inner and second strips together, thereby laminating the inner surface of the composite cover material to the outer surface of the second strip and laminating the inner surface of the second strip to the outer surface of the inner strip.
  • the invention is a method for continuously producing a multi-strip laminate paint roller.
  • An inner strip and an outer strip of material is helically advanced about a mandrel in offset relation. At least one of the strips is formed from a compound of polypropylene and calcium carbonate having between 5% and 50% calcium carbonate by weight.
  • the inner strip and the outer strip have an outer surface facing away from the mandrel.
  • the outer surface of the inner and outer strips is heated to cause a layer of the outer surface of the strips to become liquefied.
  • a cover around Prior to permitting the liquefied layers to harden and set, a cover around is wrapped around the outer strip and a compressing force is applied upon the cover urging the cover and the two strips toward the mandrel, thereby creating the continuous laminated paint roller.
  • the invention is a cold core method of making a paint roller from a cold, hard, preformed hollow core of thermoplastic material of a predetermined length in which the cold hard hollow core and its associated cover are forged together to form a single unitary body.
  • a cold hard hollow core is provided.
  • the cold hard hollow core is formed from a compound of polypropylene and calcium carbonate having between 5% and 50% calcium carbonate by weight.
  • a mandrel having an external diameter is provided. The mandrel slidably receives and makes contact with the cold hard hollow core.
  • the cold hard hollow core is rotated.
  • the exterior surface of the cold hard hollow thermoplastic rotating core is heated, by application of a single source of heat, to a temperature high enough to cause subsequently applied cover to adhere to said exterior surface.
  • a cover is then to the heated exterior surface of the cold hard hollow thermoplastic core, thereby bonding the cover to the heated exterior surface thereof, and forming a paint roller.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Laminated Bodies (AREA)

Abstract

Described are methods of making a paint roller from a compound of polypropylene and calcium carbonate having between 5% and 50% calcium carbonate by weight, and, in an embodiment, between 25% and 40%. One or various compounds may be used to form portions of, or all of the components that make up the paint roller, including, for example, the thermoplastic strips, adhesives and/or the backing of a composite cover material. The materials can be assembled in a continuous manufacturing process.

Description

  • This application includes material which is subject to copyright protection. The copyright owner has no objection to the facsimile reproduction by anyone of the patent disclosure, as it appears in the Patent and Trademark Office files or records, but otherwise reserves all copyright rights whatsoever.
  • FIELD OF THE INVENTION
  • This invention pertains to methods and apparatus for making paint rollers of the type used for applying paint to walls and the like. More specifically, the invention pertains to methods and apparatus for making component parts for use in a process of making a paint roller, and methods and apparatus for making a paint roller.
  • BRIEF DESCRIPTION OF THE DRAWINGS
  • In the accompanying drawings forming a part of this specification, and in which like reference characters are employed to designate like parts throughout the same:
  • FIG. 1 is a diagrammatic representation of a paint roller manufacturing apparatus that can be used in accordance with an embodiment of the present invention.
  • FIG. 2 is a diagrammatic representation of an apparatus for forming a composite paint roller cover having a compound backing in accordance with an embodiment of the present invention.
  • FIG. 3 is a diagrammatic representation of a multi-strip laminate paint roller manufacturing apparatus that can be used in accordance with an embodiment of the present invention.
  • FIG. 4 is a diagrammatic representation of another paint roller manufacturing apparatus that can be used in accordance with an embodiment of the present invention.
  • FIG. 5 is a diagrammatic representation of yet another paint roller manufacturing apparatus that can be used in accordance with an embodiment of the present invention.
  • DETAILED DESCRIPTION OF THE INVENTION AND EMBODIMENTS THEREOF
  • FIG. 1 shows a diagrammatic representation of a paint roller manufacturing apparatus 100. A strip of material 145 comprising polypropylene is wrapped helically about a mandrel 140 held on a base 150. The mandrel may be cooled by a cooler (not shown). An adhesive 135 comprising polypropylene is applied to an outer surface of the strip 145 by applicator 130. A cover 125 is wrapped around the mandrel 150 over the first strip 145 and the adhesive 135. A helical belt 120 driven by rollers 120 a, 120 b applies a compressive force on the cover material and advances the tubular assembly 115 down the mandrel 150. A flyaway saw 105 cuts the tubular assembly into lengths 110 that can be used, or cut and used to produce finished paint rollers.
  • Compound Adhesive
  • In an embodiment, the adhesive 135 is a compound of polypropylene and calcium carbonate having between 5% and 50% calcium carbonate by weight. In an embodiment the adhesive compound comprises at least 25% but not more than 45% calcium carbonate. In an embodiment the adhesive compound comprises at least 25% but not more than 33% calcium carbonate. In an embodiment, the calcium carbonate compounded with the polypropylene to form the compound adhesive 135 should be selected and/or processed to be relatively non-abrasive to the processing equipment.
  • In an embodiment, the applicator 130 applies a compound adhesive 135 formed by a twin screw extruder sufficient for compounding the calcium carbonate with polypropylene (not shown) from a supply of polypropylene resin in pellet form and a supply of calcium carbonate. When using a twin screw extruder, the calcium carbonate should be relatively non-abrasive to a extruder.
  • In an embodiment, the calcium carbonate compounded with the polypropylene to form the compound adhesive 135 should be used in a relatively fine, powdered form. In an embodiment the calcium carbonate may have a median particle size of 3 micrometers or less. In an embodiment, the calcium carbonate compounded with the polypropylene to form the compound adhesive 135 may be surface treated.
  • The cost by weigh of calcium carbonate is expected to be lower than the cost by weigh of polypropylene, thus the use of a compounded adhesive 135 as described will reduce the cost of manufacturing paint rollers.
  • The adhesive 135 made from a compound of polypropylene and calcium carbonate having between 5% and 50% calcium carbonate by weight is expected to have higher thermal conductivity that an adhesive made from polypropylene alone. Accordingly, an adhesive 135 made from a compound of polypropylene and calcium carbonate having between 5% and 50% calcium carbonate by weight is expected to cool and set faster than an adhesive made from polypropylene alone. As a result of the higher thermal conductivity, when the apparatus 100 is operated using an adhesive 135 made from a compound of polypropylene and calcium carbonate having between 5% and 50% calcium carbonate by weight, it is expected that the apparatus will operate at higher overall throughput than it would when using an adhesive 135 comprising more than 95% polypropylene.
  • Compound Strip Material
  • In an embodiment, the strip 145 is made of a compound of polypropylene and calcium carbonate having between 5% and 50% calcium carbonate by weight. In an embodiment the strip 145 comprises at least 25% but not more than 45% calcium carbonate. In an embodiment the strip 145 comprises at least 25% but not more than 33% calcium carbonate.
  • In an embodiment, the calcium carbonate compounded with the polypropylene to form the strip 145 should be a relatively fine, powdered form of calcium carbonate. In an embodiment the calcium carbonate compounded with the polypropylene to form the strip 145 should have a median particle size of 3 micrometers or less. In an embodiment, the calcium carbonate compounded with the polypropylene to form the strip 145 may be surface treated.
  • The cost by weigh of calcium carbonate is expected to be lower than the cost by weigh of polypropylene, thus the use of a strip 135 made from a compound of polypropylene and calcium carbonate will reduce the cost of manufacturing paint rollers made therewith.
  • The strip 145 made from a compound of polypropylene and calcium carbonate having between 5% and 50% calcium carbonate by weight is expected to have higher thermal conductivity that an adhesive made from polypropylene alone. Because of the higher thermal conductivity using a strip 145 made from a compound of polypropylene and calcium carbonate having between 5% and 50% calcium carbonate by weight, rather than a strip 145 made from more than 95% polypropylene, it is anticipated that the adhesive 135 will set faster, and thus, apparatus 100 will operate at higher overall throughput than it would when using a strip 145 comprising more than 95% polypropylene.
  • Cover Material
  • In an embodiment, the cover 250 has a fabric backing and a pile outer surface such as knitted or woven cover materials; such a fabric backing of the cover 250 comprises interstitial pores into which adhesive 135 may flow, especially when compressed by the belt 120. In an embodiment, the cover is made from a microfiber material; such a microfiber cover 250 also comprises interstitial pores into which adhesive 135 may flow, especially when compressed by the belt 120.
  • In an embodiment, the cover 250 has a pile or microfiber outer surface and a smooth or uniformly imprinted backing formed from polypropylene.
  • In an embodiment, the cover 250 has a pile or microfiber outer surface and a smooth or uniformly imprinted backing formed from a compound of polypropylene and calcium carbonate having between 5% and 50% calcium carbonate by weight. In an embodiment the cover 250 comprises at least 25% but not more than 45% calcium carbonate. In an embodiment the cover 250 comprises at least 25% but not more than 33% calcium carbonate.
  • In an embodiment, the calcium carbonate compounded with the polypropylene to form the backing of the cover 250 should be a relatively fine, powdered form of calcium carbonate. In an embodiment the calcium carbonate compounded with the polypropylene to form the backing of the cover 250 should have a median particle size of 3 micrometers or less. In an embodiment, the calcium carbonate compounded with the polypropylene to form the backing of the cover 250 may be surface treated.
  • The cost by weigh of calcium carbonate is expected to be lower than the cost by weigh of polypropylene, thus the use of the backing of the cover 250 made from a compound of polypropylene and calcium carbonate will reduce the cost of manufacturing paint rollers made therewith.
  • The backing of the cover 250 made from a compound of polypropylene and calcium carbonate having between 5% and 50% calcium carbonate by weight is expected to have higher thermal conductivity that an adhesive made from polypropylene alone. Because of the higher thermal conductivity using a cover 250 having a backing made from a compound of polypropylene and calcium carbonate having between 5% and 50% calcium carbonate by weight, rather than a backing made from more than 95% polypropylene, it is anticipated that the adhesive 135 will set faster, and thus, apparatus 100 will operate at higher overall throughput than it would when using a cover 250 having a backing comprising more than 95% polypropylene.
  • Use of Compounded Materials
  • Apparatus 100 may be operated according to the present invention using an adhesive 135 made of a compound of polypropylene and calcium carbonate having between 5% and 50% calcium carbonate by weight; using a strip 145 made of a compound of polypropylene and calcium carbonate having between 5% and 50% calcium carbonate by weight; and/or using a cover 250 having a backing made of a compound of polypropylene and calcium carbonate having between 5% and 50% calcium carbonate by weight. When more than one component is made of a compound of polypropylene and calcium carbonate having between 5% and 50% calcium carbonate by weight, the percentage of calcium carbonate used in the compound forming the adhesive 135, the strip 145 and the cover 250 backing may be the same, or may differ from one-another.
  • When compounding of polypropylene and calcium carbonate in any compound of between 5% and 50% calcium carbonate by weight, the calcium carbonate is not expected to melt. As discussed above, the resulting compounds are expected to have higher thermal conductivity. Variation in the amount of calcium carbonate are within the scope of the invention, and thus, it will be apparent to one of skill in the art that to some degree thermal conductivity can be controlled, or a desired thermal conductivity or range of thermal conductivity can be achieved by varying the percentage of calcium carbonate in the compound.
  • The compounds of polypropylene and calcium carbonate used in the adhesive 135, strip 145 and/or cover 250 are expected to have achieve other characteristics that, when compared to using polypropylene alone, are expected to include increased stiffness. Increased stiffness may give a paint roller a firmer or stiffer feel, which may improve its performance as a paint roller. Moreover, in many cases, stiffer or firmer paint rollers are sold at a higher price. It will be apparent to one of skill in the art that to some degree, stiffness can be controlled, or a desired stiffness or range of stiffness can be achieved by varying the percentage of calcium carbonate in the compound.
  • FIG. 2 shows an apparatus 200 for forming the composite paint roller cover 250 having a compound backing. The roller 220 is urged toward the frame 230 by a spring, by gravity or by other means that will be apparent to persons skilled in the art. A layer of compound adhesive 210 is dispensed by an applicator 205 onto a roller 220, and runs between the roller 220 and a frame 230, such as a tenter frame, or between the roller 220 and another roller (not shown). The layer of compound adhesive 210 dispensed onto roller 220 may be between 0.010″ and 0.020″. In an embodiment, the compound adhesive 210 is a compound of polypropylene and calcium carbonate having between 5% and 50% calcium carbonate by weight. In an embodiment the adhesive compound comprises at least 25% but not more than 45% calcium carbonate. In an embodiment the adhesive compound comprises at least 25% but not more than 33% calcium carbonate. The calcium carbonate should be relatively non-abrasive to the processing machinery.
  • The cover material 215 is advanced along the frame 205 with its pile side down, and moved beneath the roller 220. The cover material 215 may have a pile side and a fabric backing—the fabric backing being porous and having interstitial spaces sufficient to permit penetration of the compound adhesive 210. As the cover material 215 and the layer of compound adhesive 210 pass between the roller 220 and the surface of the frame 230 they are urged together. The roller-side of the compound adhesive 210 may be smoothed or uniformly imprinted (e.g., embossed) by the roller 220 as it passed underneath, thus forming a uniform or smooth adhesive layer surface 225.
  • In an embodiment, the roller 220 applies a compressive force to urge the compound adhesive 210 towards the cover material 215. In an embodiment, the compressive force is sufficient to force the compound adhesive 210 into the interstitial spaces within the fabric backing of the cover material 215. The resulting composite sheet material 235 may be cut by a cutter 240 to trim away any excess materials, and thus to form the compound composite cover material 250 with a non-porous backing.
  • In an embodiment, the roller 220 may be heated or cooled.
  • In an embodiment, the apparatus comprises an applicator 205 that applies a compound adhesive 210 formed by a twin screw extruder sufficient for compounding calcium carbonate with polypropylene (not shown) from a supply of polypropylene resin in pellet form and a supply of calcium carbonate. The calcium carbonate should be relatively non-abrasive to the twin screw extruder.
  • The positioning and angular orientation of the applicator 205 may be varied. In an embodiment, the applicator is angled between 30 degrees and 60 degrees from vertical and positioned within inches of the middle of the roller 220. In another embodiment the applicator 205 is within 30 degrees (±) of vertical, and is positioned to dispense adhesive such that the adhesive layer 210 first makes contact on the upper half of the roller 220. In yet another embodiment, the applicator 205 is within 30 degrees (±) of horizontal and is positioned to dispense adhesive such that the adhesive layer 210 first makes contact on the lower half of the roller 220. Variations in the angular orientation of the applicator 205, and its distance from and orientation around the roller are within the scope of the invention, and will be apparent to one skilled in the art.
  • FIG. 3 shows a paint roller manufacturing apparatus 300. A strip of material 345 comprising polypropylene is wrapped helically about a mandrel 340 held on a base 350. The mandrel may be cooled by a cooler (not shown). A second strip of material 348 comprising polypropylene is wrapped helically about the first strip 345. An adhesive 335 comprising polypropylene is applied to an outer surface of the strips 345, 348 by applicator 330. A cover 325 is also helically wrapped around the mandrel 350 over the strips 345, 348 and the adhesive 335. A helical belt 320 driven by rollers 320 a, 320 b applies a compressive force on the cover material and advances the tubular assembly 310 down the mandrel 350. A flyaway saw 305 may cut the tubular assembly 310 into lengths (not shown) that can be used, or further cut and used to produce finished paint rollers.
  • In an embodiment, the applicator 330 applies a compound adhesive 335 formed by a twin screw extruder sufficient for compounding the calcium carbonate with polypropylene (not shown) from a supply of polypropylene resin in pellet form and a supply of calcium carbonate. When using a twin screw extruder, the calcium carbonate should be relatively non-abrasive to a extruder.
  • Apparatus 300 may be operated according to the present invention using an adhesive 335 made of a compound of polypropylene and calcium carbonate having between 5% and 50% calcium carbonate by weight; using a strip 345 made of a compound of polypropylene and calcium carbonate having between 5% and 50% calcium carbonate by weight; using a second strip 348 made of a compound of polypropylene and calcium carbonate having between 5% and 50% calcium carbonate by weight; and/or using a cover 325 having a backing made of a compound of polypropylene and calcium carbonate having between 5% and 50% calcium carbonate by weight. When more than one component is made of a compound of polypropylene and calcium carbonate having between 5% and 50% calcium carbonate by weight, the percentage of calcium carbonate used in the compound forming the adhesive 335, the strip 345, the second strip 348 and the cover 325 backing may be the same, or may differ from one-another.
  • Variation in the amount of calcium carbonate are within the scope of the invention, and thus, it will be apparent to one of skill in the art that to some degree thermal conductivity can be controlled, or a desired thermal conductivity or range of thermal conductivity can be achieved by varying the percentage of calcium carbonate in one or more of the compounds. It will be apparent to one of skill in the art that to some degree, stiffness can be controlled, or a desired stiffness or range of stiffness can be achieved by varying the percentage of calcium carbonate in these compounds as well.
  • FIG. 4 shows a paint roller manufacturing apparatus 400. A strip of material 448 comprising polypropylene is wrapped helically about a mandrel 440 held on a base 450. The mandrel may be cooled by a cooler (not shown). A second strip of material 445 comprising polypropylene is wrapped helically about the first strip 448. The heaters 460, 455 which may employ heating elements or heat by open flame, heat the outer surface (vis-à-vis the wrapping about the mandrel) of strips 448, 445 respectively. The heat produced by the heaters 460 is sufficient to cause the outer surface of the strips 448, 445 to become tacky, or to liquefy, or to become molten. (Although shown diagrammatically at a distance from the mandrel, in an embodiment, the heaters 460, 455 should be placed as close as practicable to the point where the strips 448, 445 contact the mandrel.) A cover 415 is also helically wrapped around the mandrel 440 over the outer surface of the second strip 445. A helical belt drive 420 applies an inwardly compressive force on the cover material 415 and advances the assembly down the mandrel 440. A flyaway saw 405 may cut the assembly into lengths (not shown) that can be used, or further cut and used to produce finished paint rollers.
  • Apparatus 400 may be operated according to the present invention using a strip 448 made of a compound of polypropylene and calcium carbonate having between 5% and 50% calcium carbonate by weight; using a second strip 445 made of a compound of polypropylene and calcium carbonate having between 5% and 50% calcium carbonate by weight; and/or using a cover 415 having a backing made of a compound of polypropylene and calcium carbonate having between 5% and 50% calcium carbonate by weight. When more than one component is made of a compound of polypropylene and calcium carbonate having between 5% and 50% calcium carbonate by weight, the percentage of calcium carbonate used in the compound forming the strips 448, 445 and the cover 415 backing may be the same, or may differ from one-another.
  • Variation in the amount of calcium carbonate are within the scope of the invention, and thus, it will be apparent to one of skill in the art that to some degree thermal conductivity can be controlled, or a desired thermal conductivity or range of thermal conductivity can be achieved by varying the percentage of calcium carbonate in one or more of the compounds. It will be apparent to one of skill in the art that to some degree, stiffness can be controlled, or a desired stiffness or range of stiffness can be achieved by varying the percentage of calcium carbonate in these compounds as well.
  • FIG. 5 shows an apparatus 500 suitable for making paint rollers with a preformed core. The apparatus 500 comprises a rotating mandrel 510, a carriage 560 running on a stationary track 570 and supporting a cover material guide 550, and a heater 530. A preformed core 540 comprising polypropylene is placed about the mandrel 510. The heater 530 is activated, thereby heat softening the outer surface of the preformed core in an amount sufficient to bond to the backing of the cover 520. The cover 520 is wrapped helically about the core by the rotation of the mandrel and the movement of the carriage 560. The rotation of the mandrel 510 and the movement of the carriage 560 are such that the cover 520 is wrapped about substantially all of the preformed core 540.
  • Apparatus 500 may be operated according to the present invention using a preformed core 540 made of a compound of polypropylene and calcium carbonate having between 5% and 50% calcium carbonate by weight; and/or using a cover 520 having a backing made of a compound of polypropylene and calcium carbonate having between 5% and 50% calcium carbonate by weight. When more than one component is made of a compound of polypropylene and calcium carbonate having between 5% and 50% calcium carbonate by weight, the percentage of calcium carbonate used in the compound forming the core 540 and the cover 520 backing may be the same, or may differ from one-another.
  • Variation in the amount of calcium carbonate are within the scope of the invention, and thus, it will be apparent to one of skill in the art that to some degree thermal conductivity can be controlled, or a desired thermal conductivity or range of thermal conductivity can be achieved by varying the percentage of calcium carbonate in one or more of the compounds. It will be apparent to one of skill in the art that to some degree, stiffness can be controlled, or a desired stiffness or range of stiffness can be achieved by varying the percentage of calcium carbonate in these compounds as well.
  • It is possible, without departing from the invention, to use a compound of polypropylene and calcium carbonate having between 5% and 50% calcium carbonate by weight in lieu of polypropylene in making paint rollers. In light of this disclosure, other methods for the manufacture of the same will be apparent to persons of skill in the art.
  • Benefits of certain embodiments of the instant invention include: control of thermal conductivity in the component materials leading to faster throughput and/or faster set times; and control of material characteristics such as stiffness for manufacture of harder, more expensive paint rollers.
  • The above embodiments and preferences are illustrative of the present invention. It is neither necessary, nor intended for this patent to outline or define every possible combination or embodiment. The inventor has disclosed sufficient information to permit one skilled in the art to practice at least one embodiment of the invention, and has disclosed the ways the inventor now believes are the best ways to practice the invention. The above description and drawings are merely illustrative of the present invention and that changes in components, structure and procedure are possible without departing from the scope of the present invention as defined in the following claims.
  • Illustrative Embodiments Shown in the Figures
  • In one embodiment, the invention is a method of making a paint roller. A strip of material is helically wound around a mandrel so as to form a helically wound strip. The strip is formed from a compound of polypropylene and calcium carbonate having between 5% and 50% calcium carbonate by weight. The wound strip is advanced along the mandrel. A layer of adhesive is applied onto an outer surface of the wound strip. A strip of cover material then is helically wrapped about the wound strip and over the layer of adhesive, thereby bonding the strip of cover material to the wound strip for forming the paint roller.
  • In another embodiment, the invention is method of making a paint roller. A strip of material is helically wound around a mandrel so as to form a helically wound strip. The wound strip is advanced along the mandrel. An adhesive is compounded from polypropylene and calcium carbonate. The compound comprises between 5% and 50% calcium carbonate by weight. The layer of adhesive is applied onto an outer surface of the wound strip. A strip of cover material then is helically wrapped about the wound strip and over the layer of adhesive, thereby bonding the strip of cover material to the wound strip for forming the paint roller.
  • In another embodiment, the invention is method of making a paint roller. A strip of material helically wound around a mandrel so as to form a helically wound strip. The strip is formed from a compound of polypropylene and calcium carbonate having between 5% and 50% calcium carbonate by weight. The wound strip is advanced along the mandrel. An adhesive is compounded from polypropylene and calcium carbonate. The compound comprises between 5% and 50% calcium carbonate by weight. The layer of adhesive is applied onto an outer surface of the wound strip. A strip of cover material then is helically wrapped about the wound strip and over the layer of adhesive, thereby bonding the strip of cover material to the wound strip for forming the paint roller.
  • In another embodiment, the invention is a method for continuously producing a multi-strip laminate paint roller. An inner strip and an outer strip of material is helically advanced about a mandrel in offset relation. At least one of the strips is formed from a compound of polypropylene and calcium carbonate having between 5% and 50% calcium carbonate by weight. A layer of adhesive is applied between the two strips and on the outer surface of the outer strip. Prior to permitting the layer of liquid polypropylene to harden and set, a cover is wrapped around the outer strip and a compressing force is applied upon the cover urging the cover and the two strips toward the mandrel, thereby creating the continuous laminated paint roller.
  • In another embodiment, the invention is a method for continuously producing a multi-strip laminate paint roller. An inner strip and an outer strip of material is helically advanced about a mandrel in offset relation. An adhesive material is compounded from polypropylene and calcium carbonate, the compound comprising between 5% and 50% calcium carbonate by weight. The adhesive material is applied between the two strips and on the outer surface of the outer strip. Prior to permitting the adhesive material to harden and set, a cover is wrapped around the outer strip and a compressing force is applied upon the cover urging the cover and the two strips toward the mandrel, thereby creating the continuous laminated paint roller.
  • In another embodiment, the invention is a method for continuously producing a multi-strip laminate paint roller. An inner strip and an outer strip of material is helically advanced about a mandrel in offset relation, at least one of the strips being formed from a compound of polypropylene and calcium carbonate having between 5% and 50% calcium carbonate by weight. An adhesive material is compounded from polypropylene and calcium carbonate. The compound comprises between 5% and 50% calcium carbonate by weight. The adhesive material is applied between the two strips and on the outer surface of the outer strip. Prior to permitting the layer of liquid polypropylene to harden and set, a cover is wrapped around the outer strip and a compressing force is applied upon the cover urging the cover and the two strips toward the mandrel, thereby creating the continuous laminated paint roller.
  • In another embodiment, the invention is a method of making a composite cover material. A first width of pile material is advanced. The pile material has a pile side and a fabric backing, wherein the fabric backing is porous, having interstitial spaces or gaps. An adhesive is compounded from polypropylene and calcium carbonate. The compound comprises between 5% and 50% calcium carbonate by weight. A layer of the adhesive is applied to the fabric backing of the pile material. The adhesive layer is allowed to set to form a composite sheet material having a pile side and a non-porous backing. The composite sheet material is longitudinally cut to form one or more strips of composite cover material in a second width. The formed composite cover material has an inner surface and an outer surface, the outer surface comprising a pile, and the inner surface comprising a non-porous layer bonded thereto.
  • In another embodiment, the invention is a method of making a paint roller having one or more materials making up its core. An adhesive material is compounded from polypropylene and calcium carbonate. The compound comprises between 5% and 50% calcium carbonate by weight. The adhesive material is applied between a cover material and one or more materials making up the paint roller core. The adhesive material is permitted to harden and set, thereby creating the paint roller.
  • In another embodiment, the invention is a method of making a laminated paint roller. A strip comprising polypropylene is helically wound around a mandrel so as to form a helically wound strip, the strip having an outer surface. The wound strip is helically advanced along the mandrel. A layer of adhesive comprising polypropylene is applied onto the outer surface of the wound strip. A strip of composite cover material is then wrapped about the wound strip and over the layer of adhesive. The composite cover material is formed by method comprising the following steps. A width of porous pile material is provided having a pile side and an fabric underside. The width of pile material is advanced with the fabric underside facing up. A backing layer is compounded from polypropylene and calcium carbonate, the compound comprising between 5% and 50% calcium carbonate by weight. The backing layer is applied on the fabric underside of the advancing width of pile material so that the layer has one side that is in contact with the fabric underside of the advancing material and an other side that is not in contact with the advancing pile material, the layer being in molten form when it is applied. A compressive force is applied to the other side of the layer before the layer hardens and sets, to smooth the other side of the layer of polypropylene, and to urge the layer and the fabric underside of the pile material together, thereby forming a composite material having a smooth or uniformly imprinted non-porous side and a pile side, and wherein the pile is held fast on the composite material. The width of composite material is cut into a strip once the backing layer is no longer in molten form, thereby forming a composite cover material having an inner surface comprising a smooth or uniformly imprinted non-porous polypropylene side and a pile side. The composite cover material produced by the method described above is then used to form a laminated pain roller. A compressive force is applied from without the composite cover material to urge the composite cover material, the layer of adhesive and strip of non-porous polypropylene material together, thereby laminating the smooth inner surface of the composite cover material to the outer surface of the non-porous polypropylene strip.
  • In another embodiment, the invention is a method of making a laminated paint roller. An inner strip of thermoplastic material is helically around a mandrel so as to form a helically wound inner strip, the inner strip having an outer surface. A second strip of thermoplastic material is helically wound around a mandrel in offset relation to the inner strip, so as to form a helically wound second strip, the second strip having an inner surface and an outer surface. The wound inner and second strips are advanced along the mandrel. An adhesive is compounded from polypropylene and calcium carbonate, the compound comprising between 5% and 50% calcium carbonate by weight. A layer of the adhesive is applied onto the outer surface of the wound inner strip and the outer surface of the wound second strip. A strip of composite cover material is then wrapped about the wound second strip and over the layer of adhesive applied to the wound second strip. The composite cover material has an inner surface and an outer surface, the outer surface comprising a pile fabric, and the inner surface comprising a smooth generally non-porous backing comprising polypropylene. A compressive force is then applied from without the composite cover material to urge the composite cover material, the layer of adhesive and inner and second strips together, thereby laminating the inner surface of the composite cover material to the outer surface of the second strip and laminating the inner surface of the second strip to the outer surface of the inner strip.
  • In another embodiment, the invention is a method for continuously producing a multi-strip laminate paint roller. An inner strip and an outer strip of material is helically advanced about a mandrel in offset relation. At least one of the strips is formed from a compound of polypropylene and calcium carbonate having between 5% and 50% calcium carbonate by weight. The inner strip and the outer strip have an outer surface facing away from the mandrel. The outer surface of the inner and outer strips is heated to cause a layer of the outer surface of the strips to become liquefied. Prior to permitting the liquefied layers to harden and set, a cover around is wrapped around the outer strip and a compressing force is applied upon the cover urging the cover and the two strips toward the mandrel, thereby creating the continuous laminated paint roller.
  • In another embodiment, the invention is a cold core method of making a paint roller from a cold, hard, preformed hollow core of thermoplastic material of a predetermined length in which the cold hard hollow core and its associated cover are forged together to form a single unitary body. A cold hard hollow core is provided. The cold hard hollow core is formed from a compound of polypropylene and calcium carbonate having between 5% and 50% calcium carbonate by weight. A mandrel having an external diameter is provided. The mandrel slidably receives and makes contact with the cold hard hollow core. The cold hard hollow core is rotated. The exterior surface of the cold hard hollow thermoplastic rotating core is heated, by application of a single source of heat, to a temperature high enough to cause subsequently applied cover to adhere to said exterior surface. A cover is then to the heated exterior surface of the cold hard hollow thermoplastic core, thereby bonding the cover to the heated exterior surface thereof, and forming a paint roller.

Claims (21)

1. A method of making a paint roller, comprising the steps of:
helically winding a strip of material around a mandrel so as to form a helically wound strip, the strip being formed from a compound of polypropylene and calcium carbonate having between 5% and 50% calcium carbonate by weight;
advancing the wound strip along the mandrel;
applying a layer of adhesive onto an outer surface of the wound strip; and
helically wrapping a strip of cover material about the wound strip and over the layer of adhesive, thereby bonding the strip of cover material to the wound strip for forming the paint roller.
2. A method of making a paint roller, comprising the steps of:
helically winding a strip of material around a mandrel so as to form a helically wound strip;
advancing the wound strip along the mandrel;
compounding an adhesive from polypropylene and calcium carbonate, the compound comprising between 5% and 50% calcium carbonate by weight;
applying the layer of adhesive onto an outer surface of the wound strip;
helically wrapping a strip of cover material about the wound strip and over the layer of adhesive, thereby bonding the strip of cover material to the wound strip for forming the paint roller.
3. The method of claim 2, wherein the step of compounding is performed by a twin screw extruder.
4. A method of making a paint roller, comprising the steps of:
helically winding a strip of material around a mandrel so as to form a helically wound strip, the strip being formed from a compound of polypropylene and calcium carbonate having between 5% and 50% calcium carbonate by weight;
advancing the wound strip along the mandrel;
compounding an adhesive from polypropylene and calcium carbonate, the compound comprising between 5% and 50% calcium carbonate by weight;
applying the layer of adhesive onto an outer surface of the wound strip;
helically wrapping a strip of cover material about the wound strip and over the layer of adhesive, thereby bonding the strip of cover material to the wound strip for forming the paint roller.
5. The method of claim 4, wherein the step of compounding is performed by a twin screw extruder.
6. A method for continuously producing a multi-strip laminate paint roller comprising the steps of:
helically advancing an inner strip and an outer strip of material about a mandrel in offset relation, at least one of the strips being formed from a compound of polypropylene and calcium carbonate having between 5% and 50% calcium carbonate by weight;
applying a layer of adhesive between the two strips and on the outer surface of the outer strip;
prior to permitting the layer of liquid polypropylene to harden and set, wrapping a cover around the outer strip and applying a compressing force upon the cover urging the cover and the two strips toward the mandrel, thereby creating the continuous laminated paint roller.
7. A method for continuously producing a multi-strip laminate paint roller comprising the steps of:
helically advancing an inner strip and an outer strip of material about a mandrel in offset relation;
compounding an adhesive material from polypropylene and calcium carbonate, the compound comprising between 5% and 50% calcium carbonate by weight;
applying the adhesive material between the two strips and on the outer surface of the outer strip;
prior to permitting the adhesive material to harden and set, wrapping a cover around the outer strip and applying a compressing force upon the cover urging the cover and the two strips toward the mandrel, thereby creating the continuous laminated paint roller.
8. The method of claim 7, wherein the step of compounding is performed by a twin screw extruder.
9. A method for continuously producing a multi-strip laminate paint roller comprising the steps of:
helically advancing an inner strip and an outer strip of material about a mandrel in offset relation, at least one of the strips being formed from a compound of polypropylene and calcium carbonate having between 5% and 50% calcium carbonate by weight;
compounding an adhesive material from polypropylene and calcium carbonate, the compound comprising between 5% and 50% calcium carbonate by weight;
applying the adhesive material between the two strips and on the outer surface of the outer strip;
prior to permitting the layer of liquid polypropylene to harden and set, wrapping a cover around the outer strip and applying a compressing force upon the cover urging the cover and the two strips toward the mandrel, thereby creating the continuous laminated paint roller.
10. The method of claim 9, wherein the step of compounding is performed by a twin screw extruder.
11. A method of making a composite cover material comprising the steps of:
advancing a first width of pile material, the pile material having a pile side and a fabric backing, wherein the fabric backing is porous, and has interstitial spaces or gaps therein;
compounding an adhesive from polypropylene and calcium carbonate, the compound comprising between 5% and 50% calcium carbonate by weight;
applying a layer of the adhesive to the fabric backing of the pile material;
allowing the adhesive layer to set to form a composite sheet material having a pile side and a non-porous backing;
longitudinally cutting the composite sheet material to form one or more strips of composite cover material in a second width, the formed composite cover material having an inner surface and an outer surface, the outer surface comprising a pile, and the inner surface comprising a non-porous layer bonded thereto.
12. The method of making a composite cover material claimed in claim 11, further comprising the step of applying heat to the adhesive layer after the adhesive layer has been applied to the fabric backing, thereby at least partially smoothing an exposed surface of the adhesive layer.
13. The method of making a composite cover material claimed in claim 11, further comprising the step of applying a compressive force urging the adhesive layer toward the pile material, thereby causing at least some of the adhesive layer to fill an interstitial space or gap in the fabric backing of the pile material.
14. The method of making a composite cover material claimed in claim 13, wherein the step of applying a compressive force is performed using a roller, and the roller smoothes the adhesive layer as it applies the compressive force.
15. The method of making a composite cover material claimed in claim 13, wherein the step of applying a compressive force is performed using a roller, and the roller imprints a pattern on the adhesive layer as it applies the compressive force.
16. A method of making a paint roller having one or more materials making up its core, the method comprising the steps of:
compounding an adhesive material from polypropylene and calcium carbonate, the compound comprising between 5% and 50% calcium carbonate by weight;
applying the adhesive material between a cover material and one or more materials making up the paint roller core;
permitting the adhesive material to harden and set, thereby creating the paint roller.
17. A method of making a laminated paint roller comprising the steps of:
helically winding a strip comprising polypropylene around a mandrel so as to form a helically wound strip, the strip having an outer surface;
advancing the wound strip along the mandrel;
applying a layer of adhesive comprising polypropylene onto the outer surface of the wound strip; and
wrapping a strip of composite cover material about the wound strip and over the layer of adhesive, the composite cover material being formed by the steps of:
providing a width of porous pile material having a pile side and an fabric underside;
advancing the width of pile material with the fabric underside facing up;
compounding a backing layer from polypropylene and calcium carbonate, the compound comprising between 5% and 50% calcium carbonate by weight;
applying the backing layer on the fabric underside of the advancing width of pile material so that the layer has one side that is in contact with the fabric underside of the advancing material and an other side that is not in contact with the advancing pile material, the layer being in molten form when it is applied;
applying a compressive force to the other side of the layer before the layer hardens and sets, to smooth the other side of the layer of polypropylene, and to urge the layer and the fabric underside of the pile material together, thereby forming a composite material having a smooth or uniformly imprinted non-porous side and a pile side, and wherein the pile is held fast on the composite material;
cutting the width of composite material into a strip once the backing layer is no longer in molten form, thereby forming a composite cover material having an inner surface comprising a smooth or uniformly imprinted non-porous polypropylene side and a pile side; and
applying a compressive force from without the composite cover material to urge the composite cover material, the layer of adhesive and strip of non-porous polypropylene material together, thereby laminating the smooth inner surface of the composite cover material to the outer surface of the non-porous polypropylene strip.
18. The method of making a laminated paint roller claimed in claim 17, wherein the steps of (i) compounding a backing layer, and (ii) applying a backing layer, are performed by a twin screw extruder that receives polypropylene in pellet form from a polypropylene feeder, and receives calcium carbonate from a calcium carbonate feeder.
19. A method of making a laminated paint roller comprising the steps of:
helically winding an inner strip of thermoplastic material around a mandrel so as to form a helically wound inner strip, the inner strip having an outer surface;
helically winding a second strip of thermoplastic material around a mandrel in offset relation to the inner strip, so as to form a helically wound second strip, the second strip having an inner surface and an outer surface;
advancing the wound inner and second strips along the mandrel;
compounding an adhesive from polypropylene and calcium carbonate, the compound comprising between 5% and 50% calcium carbonate by weight;
applying a layer of the adhesive onto the outer surface of the wound inner strip and the outer surface of the wound second strip; and
wrapping a strip of composite cover material about the wound second strip and over the layer of adhesive applied to the wound second strip, the composite cover material having an inner surface and an outer surface, the outer surface of the composite cover material comprising a pile fabric, and the inner surface comprising a smooth generally non-porous backing comprising polypropylene; and
applying a compressive force from without the composite cover material to urge the composite cover material, the layer of adhesive and inner and second strips together, thereby laminating the inner surface of the composite cover material to the outer surface of the second strip and laminating the inner surface of the second strip to the outer surface of the inner strip.
20. A method for continuously producing a multi-strip laminate paint roller comprising the steps of:
helically advancing an inner strip and an outer strip of material about a mandrel in offset relation, at least one of the strips being formed from a compound of polypropylene and calcium carbonate having between 5% and 50% calcium carbonate by weight, the inner strip and the outer strip having an outer surface facing away from the mandrel;
heating the outer surface of the inner and outer strips to cause a layer of the outer surface of the strips to become liquefied;
prior to permitting the liquefied layers to harden and set, wrapping a cover around the outer strip and applying a compressing force upon the cover urging the cover and the two strips toward the mandrel, thereby creating the continuous laminated paint roller.
21. A cold core method of making a paint roller from a cold, hard, preformed hollow core of thermoplastic material of a predetermined length in which the cold hard hollow core and its associated cover are forged together to form a single unitary body comprising the steps of:
providing a hard hollow core, said hard hollow core being cold,
said cold hard hollow core being formed from a compound of polypropylene and calcium carbonate having between 5% and 50% calcium carbonate by weight,
providing a mandrel having an external diameter which slidably receives and makes contact with the cold hard hollow core,
rotating the cold hard hollow core,
heating, by application of a single source of heat, the exterior surface of the cold hard hollow thermoplastic rotating core to a temperature high enough to cause subsequently applied cover to adhere to said exterior surface,
wrapping a cover to the heated exterior surface of the cold hard hollow thermoplastic core, thereby bonding the cover to the heated exterior surface thereof, and forming a paint roller.
US12/435,946 2009-01-08 2009-05-05 Methods for manufacturing a paint roller and component parts thereof Abandoned US20100282400A1 (en)

Priority Applications (39)

Application Number Priority Date Filing Date Title
US12/435,946 US20100282400A1 (en) 2009-05-05 2009-05-05 Methods for manufacturing a paint roller and component parts thereof
US12/687,028 US8142587B2 (en) 2009-05-05 2010-01-13 Methods for manufacturing a paint roller and component parts thereof
SG2011080041A SG175418A1 (en) 2009-05-05 2010-05-05 Methods for manufacturing a paint roller and component parts thereof
CA2761109A CA2761109C (en) 2009-05-05 2010-05-05 Methods for manufacturing a paint roller and component parts thereof
ES10772768.7T ES2520365T3 (en) 2009-05-05 2010-05-05 Method of manufacturing a paint roller
HUE14183290A HUE033453T2 (en) 2009-05-05 2010-05-05 Method for manufacturing a paint roller
KR1020117028982A KR101792063B1 (en) 2009-05-05 2010-05-05 Methods for manufacturing a paint roller and component parts thereof
PCT/US2010/033734 WO2010129676A2 (en) 2009-05-05 2010-05-05 Methods for manufacturing a paint roller and component parts thereof
ES14193729.2T ES2638869T3 (en) 2009-05-05 2010-05-05 Method of manufacturing a paint roller
HUE14193729A HUE033450T2 (en) 2009-05-05 2010-05-05 Method for manufacturing a paint roller
EP17187310.2A EP3300874B1 (en) 2009-05-05 2010-05-05 Method for manufacturing a paint roller
EP10772768.7A EP2429799B1 (en) 2009-05-05 2010-05-05 Method for manufacturing a paint roller
EP14193729.2A EP2851178B1 (en) 2009-05-05 2010-05-05 Method for manufacturing a paint roller
MX2011011719A MX2011011719A (en) 2009-05-05 2010-05-05 Methods for manufacturing a paint roller and component parts thereof.
CN201710116854.XA CN106891542A (en) 2009-05-05 2010-05-05 Method of making paint roller and components thereof
PT141832907T PT2810720T (en) 2009-05-05 2010-05-05 Method for manufacturing a paint roller
ES14183290.7T ES2639102T3 (en) 2009-05-05 2010-05-05 Method of manufacturing a paint roller
EP14183290.7A EP2810720B1 (en) 2009-05-05 2010-05-05 Method for manufacturing a paint roller
BRPI1011405A BRPI1011405A2 (en) 2009-05-05 2010-05-05 methods for manufacturing a paint roller and component parts thereof
SG10201402967UA SG10201402967UA (en) 2009-05-05 2010-05-05 Methods for manufacturing a paint roller and component parts thereof
PL14183290T PL2810720T3 (en) 2009-05-05 2010-05-05 Method for manufacturing a paint roller
PL10772768T PL2429799T3 (en) 2009-05-05 2010-05-05 Method for manufacturing a paint roller
PL14193729T PL2851178T3 (en) 2009-05-05 2010-05-05 Method for manufacturing a paint roller
CN201080031052.5A CN102740984B (en) 2009-05-05 2010-05-05 Method of making paint roller and components thereof
PT141937292T PT2851178T (en) 2009-05-05 2010-05-05 Method for manufacturing a paint roller
US13/081,103 US8764928B2 (en) 2009-05-05 2011-04-06 Methods for manufacturing a paint roller and component parts thereof with strips of compounded material
US13/081,114 US8486211B2 (en) 2009-05-05 2011-04-06 Methods for manufacturing a paint roller and component parts thereof having a composite cover formed of compounded material
CL2011002771A CL2011002771A1 (en) 2009-05-05 2011-11-04 Methods for the manufacture of a laminated paint roller, comprises helically winding a polypropylene and calcium carbonate strip on a mandrel, advancing the rolled strip along the mandrel, applying a layer of polypropylene and calcium carbonate adhesive on a surface outer strip and wrapping a cover material over the rolled and adhesive strip; Methods for Continuously Producing a Multi Strip Laminated Paint Roller
CR20110584A CR20110584A (en) 2009-05-05 2011-11-08 METHODS FOR THE MANUFACTURE OF A PAINT ROLLER AND ITS COMPONENTS
US13/402,174 US8308884B2 (en) 2009-05-05 2012-02-22 Methods for manufacturing a paint roller and component parts thereof
US13/431,597 US8771451B2 (en) 2009-01-08 2012-03-27 Methods for manufacturing a paint roller and component parts thereof
US13/441,546 US20120286448A1 (en) 2009-01-08 2012-04-06 Methods for manufacturing a paint roller and component parts thereof
HK12109216.5A HK1168322A1 (en) 2009-05-05 2012-09-19 Methods for manufacturing a paint roller
US14/225,086 US9126369B2 (en) 2009-05-05 2014-03-25 Methods for manufacturing a paint roller and component parts thereof with strips of compounded material
US14/225,101 US9126370B2 (en) 2009-05-05 2014-03-25 Methods for manufacturing a paint roller and component parts thereof with composite cover having compounded material
US14/225,114 US9266283B2 (en) 2009-05-05 2014-03-25 Methods for manufacturing a paint roller and component parts thereof with adhesive of compounded material
US14/789,723 US9586374B2 (en) 2009-05-05 2015-07-01 Methods for manufacturing a paint roller and component parts thereof with composite cover material
HK15109451.6A HK1208645A1 (en) 2009-05-05 2015-09-25 Methods for manufacturing a paint roller and component parts thereof
HK18112676.6A HK1253379A1 (en) 2009-05-05 2018-10-03 Methods for manufacturing a paint roller

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